System and method for processing crop materials into livestock feed and the product thereof

ABSTRACT

A system and method for producing a feed product, and the product, are disclosed. A processor apparatus may comprise a housing and at least two rolls rotatably mounted on the housing, with a gap between the rolls through which the path of the crop materials passes. At least one roll may have alternating longitudinal ridges and grooves forming teeth on the surface of the roll. A rotating assembly may rotate the rolls with respect to the housing, and may rotate the rolls at different rotational speeds. A method may comprise cutting plants growing in a field, chopping the plants of the crop materials in a manner to produce pieces of the plants that have lengths of approximately 1 inch to approximately 2.5 inches long, and processing the plant pieces between the rolls rotating at a speed differential of at least 10 percent.

REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional patentapplication No. 61/470,681, filed Apr. 1, 2011, which is herebyincorporated by reference in its entirety.

BACKGROUND

1. Field

The present disclosure relates to the production of livestock feed andmore particularly pertains to a new system and method for processingcrops materials into livestock feed for providing a feed that is morereadily digested by livestock, such as ruminant animals, and thatparticularly provides fiber that is more effectively digested by theanimal.

2. Description of the Prior Art

Crop materials may be harvested and processed to produce silage, and insometimes a forage harvester apparatus is used to harvest the cropmaterials from the field and perform some degree of processing of thecrop materials in a manner that facilitates the formation of the silagebefore the materials are loaded into a storage container such as a siloor bag for fermentation. Typically, although not necessarily, theprocessing of the crop materials performed by the forage harvesterincludes cutting or chopping the crop materials into small pieces andcrushing the crop materials to open the kernels present in the harvestedmaterials.

Often the forage harvester includes a cutting or chopping stage and aprocessing stage. The apparatus of the chopping stage may include a drumor cutterhead that has a plurality of knives that are positioned in aspaced relationship along the circumference of the drum to cut the cropmaterials as the materials pass over a stationary shear bar inside theharvester. In many cases, the crop materials are cut into pieces thatare relatively short, in the range of approximately 0.375 inches(approximately 9.5 mm) to approximately 0.75 inches (approximately 19mm) long. The chopped crop material then moves to the apparatus of theprocessing stage which typically includes a pair of relatively closelyspaced and generally cylindrical rolls with teeth that are intended tocrush and open the kernels in the crop materials to enhance thenutritional availability of the kernels in the resultant feed.

SUMMARY

In view of the foregoing, the present disclosure describes a new systemand method for processing crops materials into livestock feed which maybe utilized to produce a feed that is more readily digested bylivestock, such as ruminant animals, and that particularly providesfiber that is more effectively digested by the animal.

The present disclosure relates in one aspect to a method for processingcrop materials to produce a feed product that provides the ingestinganimal with a greater amount of available or effective fiber than usingheretofore known methods of processing similar materials, and providesat least portions of the feed sp processed in a physical form thatfacilitates the natural ability of the animal to digest the fiber is auseful manner. A system is also disclosed that incorporates elementsthat provide the aspects of the method of producing the feed product.

In another aspect, the disclosure relates to a processor apparatus forprocessing crop materials into feed for livestock, with the processorapparatus being positionable in a forage harvester defining a path formoving crop materials cut from a field. The processor apparatus maycomprise a housing for extending at least partially about the path ofthe crop materials, and at least two generally cylindrical rolls mountedon the housing. The rolls may be rotatable to move the crop materialsthrough the housing, with a gap being formed between the rolls throughwhich the path of the crop materials passes. At least one of the rollsmay have a plurality of alternating longitudinal ridges and longitudinalgrooves forming teeth on the surface of the roll. A rotating assemblymay be configured to rotate the rolls with respect to the housing, therotating assembly being configured to rotate the pair of rolls atdifferent rotational speeds.

In still another aspect, the disclosure relates to a system forproducing a feed product that may comprise a forage harvester defining apath for crop materials harvested from a field. The forage harvester mayinclude a header apparatus for receiving and cutting plants in a fieldover which the harvester moves to thereby provide crop materials movedon the path through the harvester, with the crop materials comprisingelements of the harvested plant including plant stalks and kernels. Theforage harvester may also include a chopper apparatus receiving cropmaterials on the path from the header apparatus, and the chopperapparatus may comprise a shear bar over which the crop materials fromthe header apparatus pass, with the shear bar having a cutting edge. Thechopper apparatus may also comprise a rotating cutterhead having aplurality of knives mounted on the circumference of cutterhead and beingmovable proximate to the cutting edge of the shear bar to cut cropmaterials passing over the shear bar. The cutterhead may be configuredto cut plant stalks of the crop materials to lengths of approximately 1inch to approximately 2.5 inches.

In yet another aspect, the disclosure relates to a method of producingfeed for animals that may comprise cutting plants growing in a field bya header apparatus and placing the plants as crop materials on a paththrough a forage harvester, chopping the plants of the crop materials ina manner to produce pieces of the plants that have lengths ofapproximately 1 inch to approximately 2.5 inches long, and processingthe plant pieces of the crop materials between rolls of a processorapparatus rotating at a speed differential of at least 10 percent.

The disclosure also relates to feed produced using the disclosure.

There has thus been outlined, rather broadly, some of the more importantelements of the disclosure in order that the detailed descriptionthereof that follows may be better understood, and in order that thepresent contribution to the art may be better appreciated. There areadditional elements of the disclosure that will be described hereinafterand which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment orimplementation in greater detail, it is to be understood that the scopeof the disclosure is not limited in its application to the details ofconstruction and to the arrangements of the components of the systems,and the particulars of the steps of the methods, set forth in thefollowing description or illustrated in the drawings. The disclosure iscapable of other embodiments and implementations and is thus capable ofbeing practiced and carried out in various ways. Also, it is to beunderstood that the phraseology and terminology employed herein are forthe purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present disclosure. It is important,therefore, that the claims be regarded as including such equivalentconstructions insofar as they do not depart from the spirit and scope ofthe present disclosure.

The advantages of the various embodiments of the present disclosure,along with the various features of novelty that characterize thedisclosure, are disclosed in the following descriptive matter andaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be better understood and when consideration is givento the drawings and the detailed description which follows. Suchdescription makes reference to the annexed drawings wherein:

FIG. 1 is a schematic diagram of a new system for processing cropsmaterials into livestock feed according to the present disclosure.

FIG. 2 is a schematic side sectional view of a processor apparatus,according to an illustrative embodiment.

FIG. 3 is a schematic perspective view of one highly suitable processorroll design for use with the present disclosure.

FIG. 4 is a schematic side view of the processor roll design shown inFIG. 3.

FIG. 5 is a schematic enlarged view of a portion of the side view ofFIG. 4.

FIG. 6 is a schematic longitudinal sectional view of the processor rollof FIG. 4 taken along line 6-6 of FIG. 4.

FIG. 7 is a schematic end view of the processor roll shown in FIG. 3.

FIG. 8 is a schematic flow diagram of a method according to the presentdisclosure.

DETAILED DESCRIPTION

With reference now to the drawings, and in particular to FIGS. 1 through8 thereof, a new system and method for processing crops materials intolivestock feed embodying the principles and concepts of the disclosedsubject matter will be described.

Broadly, the disclosure is generally directed to modifications ofconventional silage chopping and processing apparatus and methods forproducing a silage product that is more suitable for digestion bylivestock, and in particular animals having rumen-based digestivesystems such as cattle. While heretofore the focus of the chopping andprocessing of the crop materials has been on breaking up the kernels andcobs of the crop materials, the system and method of the presentdisclosure additionally focuses upon the form of the plant stalks, andin particular the size and character of the plant stalk pieces that areproduced, to increase the nutritional value of the stalk pieces to theingesting animals. In particular, the degree to which the fiber of theplant stalks may be effectively digested by the animal is enhanced.

A system 10 with suitable elements for producing a feed product with thedesired characteristics may include a forage harvester 12 that mayinclude a header apparatus 14 for cutting the plants in the field overwhich the harvester 12 is moving to thereby provide the crop materialsthat are moved through the harvester. The form of the header apparatus14 is typically designed for the harvesting of a particular type of cropbeing harvested, but will not be further described here. Once cut fromthe ground in the field, the crop materials may include the variouselements of the harvested plant, such as the plant stalk, leaves,kernels, cobs, as well as other plant matter.

The crop materials are moved from the header apparatus 14 through theharvester 12 to a chopper apparatus 16 that typically includes arotating cutterhead or drum that includes a plurality of blades orknives mounted on the circumference of the drum to cut or chop the cropmaterials passing over a shear bar. The knives are spaced along thecircumference of the cutterhead so that a knife passes across the shearbar at intervals as the crop materials pass over the shear bar.Cutterheads or drums that are suitable for modifying for the disclosedsystem are known, as well as suitable shear bar designs.

The chopped crop materials are then moved to a processor apparatus 18that includes two generally cylindrical rolls 20, 22 in a housing 24,and a rotating assembly 25 may be utilized to rotate the rolls withrespect to the housing. The rotating assembly 25 typically receivesrotational input from the engine of the harvester through, for example,a series of belts, chains or gears, but could include a dedicated motorfor rotating the rolls substantially directly. The rotating rolls movethe materials through the housing of the processor. One or both of theprocessor rolls has a plurality of alternating ridges 26 and grooves 28that form teeth on the surface of the roll. The crop materials may thenpass through an accelerator apparatus 30 to facilitate movement throughthe harvester, although the presence of an accelerator is not criticalto the systems and methods of the disclosure.

Applicants have determined that conventional silage processing apparatusand methods are primarily directed to maximizing the percentage ofkernels of the crop materials that are opened by passing through thekernel processor apparatus of the forage harvester employed to gatherand process the crop materials, but that efforts focusing solely on thetask of kernel opening tend to produce pieces of the plant stalk thatare difficult to digest by livestock having rumen-based digestivesystems. The efforts to create systems that more effectively crush thekernels may thus be counter-productive to the goal of producing betterdigestion of the feed by the animal by making the stalks of the plant,and particularly the fiber thereof, less digestible by the animal.

Applicants have recognized that the conventional chopping and processingapparatus configurations, primarily designed for maximum kernel rupture,tend to over process the stalk pieces by crushing the pieces, and thecrushed stalk pieces tend to make the fiber of the stalk less availableto be digested by the animal, and thereby providing less effective fiberfor the animal's nutrition. As a result, in addition to the processedcrop materials (e.g., in the form of silage) fed to the animal,supplemental feed may also need to be fed to make up for the fiber thatis present in the stalk pieces but not effectively digested by theanimal's digestive process.

For example, to achieve greater kernel opening effectiveness, thesubstantially cylindrical rolls of the processor apparatus have beenmoved closer together in order to maximize the percentage of the kernelsin the crop materials that are fractured or ruptured as the materialspass between the rolls. Applicants have determined that, as a result ofmoving the rolls of the kernel processor very close together, the stalksof the crop materials have been ground or crushed into a form that, wheningested by ruminant animal, tends to settle relatively quickly to thebottom of the chamber or chambers of the ruminant animal's digestivesystem. Thus, the crushing of the stalk pieces in turn tends tointerfere with the ability and effectiveness of the animal's digestivesystem to digest the fiber in the plant stalks, making the fiber in thestalks less available and thus less beneficial to the animal, and canlead to ill effects on the animal beyond the loss of the nutritive valueof the fiber.

Applicants have recognized that it would be desirable to develop andutilize a system and method which produces silage that not onlymaximizes the number of kernels that are opened, but that also providesplant stalk pieces that have fiber in a form that is more effective andsuited to the digestion process of the animal. Applicants havedetermined that a product that is more digestible may be produced bycontrolling one or more of a number of factors or parameters of theharvesting and processing process that are different and foreign to theconventional manner of harvesting and processing the forage plants. Thisnew system and method produces a new feed product that includes plantstalks that have a physical form that is markedly different from theform of plant stalks from crop materials that are harvested andprocessed in the conventional manner. Thus, using the same cropmaterials as an input, a feed product with more digestible fiber may beproduced by controlling select parameters of the chopping and processingof the materials.

In some implementations, the feed product has stalk pieces with aphysical form that may be characterized by being relatively flattenedfrom the characteristic generally cylindrical shape of the stalk piecesin the unprocessed form. The stalk pieces may be generally split in alengthwise direction, and the fibers of the stalk pieces in the producttend to be torn from each other so that some fibers of the stalk pieceremain together in a group, but the fibers may be thinly connected toeach other or to the fibers of other groups. The processed stalk pieceof the product may thus be separated into two or more collections of thefibers of the plant, with some fibers connecting the collectionstogether. The constituent fibers of the stalk piece may thus be at leastpartially torn from each other, although groups of the fibers may remainconnected together despite the tearing that has occurred. Thecollections of fibers from the split stalk piece may form a structurewith a mat-like appearance.

The stalk pieces with the general physical form and characteristicsdisclosed herein may provide more effective fiber to the ingestinganimal by increasing the amount of surface area of the plant stalk thatis exposed to the digestive fluids and microbes of the animal'sdigestive tract and therefore increases the ability of the digestivefluids to contact and act upon the plant stalk fibers. These elements ofthe animal's digestive tract are thus able to act more effectively uponthe ingested fiber. For example, the relatively higher amount of surfacearea increases the extent of the plant stalk fibers exposed to themicrobes for being acted upon by the microbes inhabiting the gut of theanimal. Further, the plant stalk pieces of the form described herein maydescend more slowly through the digestive fluids in the pouches of thedigestive tract, which facilitates the action of the fluids and microbeson the plant stalk fibers. Slowing the passage rate of the fibersthrough the tract increases the time that the fibers are exposed to thefluids and microbes in the tract and thus the time that these elementsare able to act upon the fibers. This characteristic is in contrast tostalk fibers processed by more conventional methods, which present afairly compact crushed mass with less surface area for the digestivefluids to act upon, and are also relatively quicker to descend to thelower reaches of the compartments of the gut of the ingesting animalwhich may reduce the time that the digestive fluids and microbes have toact upon the fibers.

The applicants have found that one significant parameter of theharvesting and processing of the crop materials is the length of thepieces into which the plants of the crop materials, and in particularthe plant stalks, are chopped or cut before further processing. For thepurposes of this disclosure, the length of the pieces is generallymeasured in a direction parallel to the longitudinal length of the uncutplant stalk. Generally, the length represents a maximum length that isproduced by the procession, as some pieces of shorter lengths are alsolikely to be produced by the disclosed systems and processes, and somepieces of longer lengths may also be produced, but in significantlysmaller percentages of the total mass of plant stalks cut.

In some implementations, pieces of the plant stalks produced by thesystems and methods of the disclosure may have lengths in the range ofapproximately 1 inch (approximately 26 mm) to approximately 2.5 inches(approximately 60 mm), while being relatively finely ground inthickness. In some further implementations, the fibers of the stalks ofthe processed crop materials may have lengths in the range ofapproximately 1.25 inches (approximately 32 mm) to approximately 1.5inches (approximately 38 mm). The preferred piece lengths are incontrast to the length of plant stalk fibers produced by conventionalforage harvester set ups that generally have fiber lengths ofapproximately 0.375 inches (approximately 9.5 mm) to approximately 0.75inches (approximately 19 mm) long.

To provide stalk pieces with lengths that are generally longer thanconventionally utilized, in some implementations of the system thecircumferential separation or spacing between the blades of the drum ofthe chopper apparatus of the forage harvester is increased. In someembodiments of the chopping apparatus, the increase in circumferentialseparation distance may be produced by removing alternate blades fromthe drum of the chopper to effectively generally double the length ofthe cut pieces as compared to what would have been produced otherwise.It will be appreciated that other suitable manners of forming the longerstalk piece lengths may be utilized.

Cutting the crop materials, and in particular the plant stalks, intolonger pieces than conventional may change the manner in which the stalkpieces are handled by the processor and the physical form of the piecesoutput by the processor. The cut stalk pieces with the longer lengthtend to be processed by a processor apparatus in a manner that isdifferent from pieces that have a shorter length, and as a result tendto exit the processor in a form that is different than when the pieceshave a shorter length. More specifically, the stalk pieces with longerlengths tend to travel through the processor with their longest axisoriented substantially parallel to the direction that the pieces aremoving through the processor. This movement orientation tends to causean end of the stalk piece to enter the processor and pass between theprocessor rolls, first with an initial or forward end and then theremainder of the piece follows with the end opposite the initial end, orrearward end, passing between the rolls last. The movement of the piecein a longitudinal manner through the processor tends to produce piecesof plant stalk that are split into pieces in the length wise direction,or parallel to the longitudinal length of the plant stalk piece. Thus,the plant stalk pieces have approximately the same length after beingprocessed than before being processed using the systems and processes ofthe disclosure and are not compressed lengthwise. This lengthwisemovement may at least partially contribute to the physical form of theprocessed stalk pieces that is described herein for the feed product. Itwill be appreciated that the increase in the length of the stalk piecesproduced by the chopper does not affect the degree to which the kernelsare opened by the processor.

Another parameter that may also contribute to the unique character ofthe stalk pieces produced by the system and process of the disclosure isthe size of the rolls utilized in the kernel processor that acts uponthe stalk pieces as well as the kernels of the crop materials passingthrough the processor. Conventional processor apparatus generallyutilize rolls that have diameters of approximately 10 inches(approximately 250 mm) diameter or less. In the many preferredembodiments of the system, the processor apparatus 18 includes at leastone roll, and in many embodiments a pair of the rolls, having a diameterthat is larger than conventional processor rolls, and may have adiameter (D) that is greater than approximately 10 inches (approximately250 mm) in size, and may be approximately 12 inches (approximately 300mm) or larger in size, and in many implementations may have a diameterof approximately 12 inches (approximately 300 mm) to approximately 16inches (approximately 400 mm).

The employment of rolls in the processor apparatus that have relativelylarger diameters provides a greater surface area of the roll that is incontact with the crop materials moving between the rolls at any onetime. The greater surface area in contact with the stalks may result ina longer time period of contact with the stalks, and a longer time forthe roll to act on the stalk to provide a greater chance for and degreeof tearing the stalk into constituent fibers or groups of fibers. Therelatively larger diameter of the rolls also reduces the pinch anglebetween the crop materials moving between the rolls and the surface ofthe rolls, which may reduce crushing of the stalk pieces. The increasedroll diameter may also provide greater consistency or uniformity in thephysical form of the crop materials passing out of the processorapparatus.

As an additional benefit, the relatively larger diameter of the rollsallows the rolls to rotate at a slower rotational speed that producessubstantially the same speed of movement of the surface of the roll, andthus the same speed of movement of the crop materials through theprocessor, but the slower rotational speed reduces wear on thecomponents of the processor apparatus.

Another parameter of the system and process that may contribute to thecharacter of the stalk pieces in the output of the processor is thecharacter of the surface of the rolls, and the grooves or groovingformed on the surface of at least one of the rolls, and in manypreferred embodiments, grooving formed on the surfaces of both of therolls, of the processor apparatus. The grooves on the roll surface formteeth-like projections formed by alternating grooves and ridges on thesurface that extend in a generally longitudinal direction on the rolland may extend from one end of the roll to the other end of the roll. Insome of the most preferred embodiments, the teeth-like projections havea cross sectional shape similar to a saw-tooth, and in some furtherembodiments, the saw-tooth-shaped teeth of one roll may be orientedoppositely to the saw-tooth-shaped teeth of the other roll (see FIG. 2).The density of ridges or teeth on a roll may be defined as the number ofridges per distance measured along the circumference of the roll, suchas ridges or teeth per inch of circumference. The size and density ofthe teeth may be approximately 3 ridges or teeth per inch (approximately1.2 teeth per cm) to approximately 8 teeth per inch (approximately 3.2teeth per cm), and while this tooth size and density is highlypreferable, other sizes and densities for the teeth may be employed.This range of ridge or tooth density, and the resulting tooth size, maycontribute to the tearing of the fibers of the plant stalk material awayfrom each other, particularly in combination with the longer time ofcontact between the larger rolls and the stalks of the crop materials.

Another parameter of the system that may contribute to the desiredcharacter of the stalk pieces is the difference or differential in therotational speeds of the rolls as the crop material passes therebetween,as a difference in the rotational speeds of the rolls furthercontributes to the tearing of the fibers of the stalk from each other. Ahigher or greater differential between rotational speeds is believed toincrease the tearing of the fibers of the stalk from each other andproduce the desired physical form described herein that enhances theavailability of the fiber to the digestive system of the animal. In manypreferred implementations, the rotational speed differential is betweenapproximately 10 percent and approximately 200 percent, so that, withrespect to the rotational speed of one roll, the rotational speed of theother roll may be approximately 10 percent faster to approximately 200percent faster.

Another parameter that may be effective in producing the desiredphysical form or character of the processed plant stalks is the spacingof the rolls from each other. Generally, the axes of rotation of therolls of the processor apparatus are substantially parallel to eachother, and the rolls are spaced from each other to form a gaptherebetween that is substantially uniform in width along the length ofthe rolls. The size of the gap may also contribute to the degree towhich the fibers of the stalk pieces are torn from each other,particularly where the stalk pieces move through the gap with thelongitudinal axis of the pieces aligned with the direction of movementof the pieces. Further, the relative closeness of the rolls contributesto the beneficial flattening of the stalk pieces without excessivecrushing of the pieces. While the closeness of the rolls may tend tocrush stalk pieces with shorter lengths into a less digestible mass offiber, the relatively longer length of the stalk pieces of thedisclosure tend to resist crushing as the fibers are pulled apart ratherthan staying together, particularly in the context of the otherparameters of the processor disclosed herein. In some implementations ofthe system and method, the spacing of the rolls with respect to eachother, and thus the gap (G) therebetween, may be in the range ofapproximately 0.01 inches (approximately 0.25 mm) to approximately 0.1inches (approximately 3 mm), which is highly preferable for obtainingthe desired character of the stalk pieces, as well as ensuring that alarge percentage of the kernels present in the crop materials arecrushed, although other spacings may also be used. As will be describedbelow, other characteristics of the system may affect the suitable rangeof roll spacings.

Another characteristic of the rolls that may provide more effectiveshredding of the plant stalk material is the character of the ridges 26that form the teeth-like projections between thelongitudinally-extending grooves 28. In many embodiments of the rolls,the ridges 26 extend for the entire, or substantially the entire, lengthof the roll between the ends of the roll where the mounting shaftsextend from the roll. In some further embodiments, the outer edges 32 ofthe ridges (which form the primary contact point for the materials beingprocessed) may be continuous along a line that extends substantiallyfrom one end of the roll to the other. In other embodiments, the outeredges 32 of the ridges 26 may be interrupted by gaps and thus the outeredge of the ridge may be intermittent or segmented between the ends ofthe roll. As shown in FIGS. 3 through 7, one or both of the pair ofrolls 20, 22 of the processor may have one or more circumferentialgrooves 34 formed in the roll that cross the longitudinally-extendingridges 26 and grooves 28. For example, the circumferential groove 34 maybe formed in the circumference of the roll along a helical path thatintersects and cuts across the ridges of the roll that are formed ordefined by the longitudinally-extending grooves 28. In otherembodiments, a series of circular circumferential grooves may be formedbetween the ends of the roll at uniform or non-uniform spacings withrespect to each other. The circumferential groove 34 or grooves may havea depth that is greater than the depth of the longitudinally-extendinggrooves 28, although this is not critical. The circumferential grooves34 may form segmented teeth 36 on the outer edges 32 of the ridges 26that improve the ability of the roll to produce the desired shredding ofthe plant stalks into pieces of the desired character.

The teeth 36 that are formed by the combination of thelongitudinally-extending and circumferential grooves may have outeredges that are short linear edges, or lands, that extend in alongitudinal direction of the roll. Illustratively, the profile of atooth may have a truncated pyramid shape in a longitudinal cross section(see FIG. 6) and may have a full (or substantially full) pyramid shapein a lateral cross section (see FIG. 7). In some embodiments, thecircumferential grooves 34 may be substantially V-shaped, and the sidesurfaces 38, 39 of the groove may be substantially identical in size andshape, although this is not critical, and some truncation of the bottomof the V-shaped groove may be utilized. In some embodiments, thelongitudinally-extending grooves 28 may have a configuration in whichthe side surfaces 40, 41 are not substantially identical, and one sidesurface 41 may be larger than the other side surface 40 such that theteeth appear to lean or lead toward one circumferential direction andaway from the opposite circumferential direction.

In some embodiments, the longitudinal lengths of the tooth segments orteeth 36 are less than approximately 1 inch (approximately 2.5 cm), andin some other embodiments the longitudinal lengths of the segments maybe from approximately 0.125 inches (approximately 0.3 cm) toapproximately 0.75 inches (approximately 2 cm). Further, in someembodiments the depth of the circumferential groove or grooves (asmeasured from the outermost extent of the ridges) is less thanapproximately 0.5 inches (approximately 1.3 cm) and may be fromapproximately 0.02 inches (approximately 0.05 cm) to approximately 0.25inches (approximately 0.65 cm). Further, some embodiments of the rollsmay have V-shaped circumferential grooves 34 that range fromapproximately 30 degrees to approximately 120 degrees between the sidesurfaces 38, 39 of the groove, and in some embodiments may be fromapproximately 40 degrees to approximately 100 degrees between the sidesurfaces of the groove.

Rolls that include the circumferential grooves have relatively shorterouter edges on the lands of the teeth 36 that facilitate the penetrationof the tooth into the plant stalk as compared to rolls having longerlands such as on a ridge that is continuous between the roll ends. Therelatively smaller outer edge 32 of the land is able to tear the stalkapart as a land on the opposite roll pierces the stalk fromsubstantially the opposite direction. As a result of the easierpenetration and more effective tearing provided by the shorter lands,less pressure is needed to be exerted by the rolls against the plantstalks and the rolls of the processor can be spaced further apart fromeach other while still providing an effective level of tearing andshredding of the plant stalk. Consequently, the relatively larger gapbetween the rolls may require less power to drive the rolls because thecrop material is not crushed to as great a degree before it is shredded.Also, the wider roll gap imposes less stress on the rolls, and thus theteeth of the roll tend to remain sharp for a longer period, whichresults in less cost to the user for roll maintenance and replacement.The relatively wider gap between rolls also allows the processor tooperate more quietly due to less air turbulence being created betweenthe rolls. Also, greater throughput is achieved using the wider gap,allowing the harvester to move at a faster rate through the field atharvest.

Illustratively, a pair of rolls lacking the circumferential groove mayhave a gap therebetween of approximately 0.04 inches (approximately 1mm) to approximately 0.08 inches (approximately 2 mm), and a pair ofrolls having the circumferential groove may have a gap therebetween ofapproximately 0.12 inches (approximately 3 mm) and approximately 0.24inches (approximately 6 mm) and in some of the more preferredembodiments, a gap of approximately 0.14 inches (approximately 3.5 mm)to approximately 0.22 inches (approximately 5.5. mm).

Even with the wider gap, the combination of coarse and fine rollsoperated together, with the short lands at a suitable spacing betweeneach other, help to ensure that the kernels of the crop materials arealso ground into pieces as the plant stalks are torn and shredded.

Applicants have recognized that processing the crop materials in themanner of the present disclosure, and particularly with relativelylonger length of the stalk pieces, tends to be more difficult to processby the processor apparatus of the forage harvester, and stronger andmore durable components may need to be employed in the processorapparatus. Further, as the rolls of the processor are spring biasedtoward each other, the biasing force applied to the rolls may need to beincreased, and the biasing elements, such as springs, may need to bestrengthened as compared to conventional processors.

In another aspect, the disclosure includes methods of processing cropmaterials including the plant materials using various aspects disclosedor suggested herein to provide a feed that is highly suitable fordigestion by ruminant animals. The method may include, for example,cutting plants that are growing in a field by using a header apparatusand placing the plants of the crop materials on a path through a forageharvester, and chopping the plants of the crop materials in a mannerdisclosed that produces pieces of the plants that have the lengthsdisclosed, and processing the plant pieces between rolls of a processorapparatus rotating at a speed differential to facilitate the tearing ofthe plant materials of at least 10 percent.

In still another aspect, the disclosure includes the feed produced bythe systems and apparatus having the various aspects disclosed orsuggested herein, and by methods including the various aspects ofhandling also disclosed or suggested herein.

It should be appreciated that in the foregoing description and appendedclaims, that the terms “substantially” and “approximately,” when used tomodify another term, mean “for the most part” or “being largely but notwholly or completely that which is specified” by the modified term.

It should also be appreciated from the foregoing description that,except when mutually exclusive, the features of the various embodimentsdescribed herein may be combined with features of other embodiments asdesired while remaining within the intended scope of the disclosure.

With respect to the above description then, it is to be realized thatthe optimum dimensional relationships for the parts of the disclosedembodiments and implementations, to include variations in size,materials, shape, form, function and manner of operation, assembly anduse, are deemed readily apparent and obvious to one skilled in the artin light of the foregoing disclosure, and all equivalent relationshipsto those illustrated in the drawings and described in the specificationare intended to be encompassed by the present disclosure.

Therefore, the foregoing is considered as illustrative only of theprinciples of the disclosure. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the disclosed subject matter to the exact constructionand operation shown and described, and accordingly, all suitablemodifications and equivalents may be resorted to that fall within thescope of the claims.

We claim:
 1. A method of producing a silage feed for animals having arelatively long physically effective fiber obtained from cut and tornplant stalks, the method comprising: cutting plants growing in a fieldby a header apparatus and placing the plants as crop materials on a paththrough a forage harvester; chopping the plants of the crop materials ina manner to produce pieces of the plants that have lengths ofapproximately 1 inch to approximately 2.5 inches long; and processingthe plant pieces of the crop materials between rolls of a processorapparatus rotating at a speed differential of at least 10 percent,wherein the rolls are positioned with a gap in between of approximately0.01 inches to approximately 0.24 inches, the first roll includes aplurality of alternating longitudinal ridges and grooves and at leastone circumferential groove having a depth of less than 0.5 inches thatcrosses the longitudinal ridges and grooves to form a plurality of gapsalong the longitudinal ridges to form tooth segments between the ends ofthe first roll, the tooth segments substantially extend in alongitudinal direction of the roll, and the tooth segments havelongitudinal lengths of less than 1 inch and have smaller outer edgesforming sharp cutting teeth far easier penetration and effective tearingof plant stalk while the rolls of the processor are spaced apart.
 2. Themethod of claim 1, wherein a density of ridges on the rolls isapproximately 3 ridges per inch to approximately 8 ridges per inch. 3.The method of claim 1 wherein processing further comprises: providingthe rolls of the processor apparatus with diameters greater thanapproximately 10 inches.
 4. The method of claim 1 wherein processingfurther comprises: providing the rolls of the processor apparatus withat least one V-shaped circumferential groove.
 5. The method of claim 1additionally comprising feeding the processed pieces of plants to aruminant animal.
 6. The method of claim 1 wherein processing furthercomprises providing the rolls of the processor apparatus withalternating ridges and grooves and a density of ridges on the rolls isapproximately 3 ridges per inch to approximately 8 ridges per inch;wherein processing further comprises providing the rolls of theprocessor apparatus with diameters greater than approximately 10 inches;and wherein processing further comprises providing each of the rollswith at least one circumferential groove.
 7. The method of claim 1,wherein the at least one circumferential groove is a spiral groove.
 8. Amethod of producing a silage feed for animals having relatively longphysically effective fiber obtained from cut and torn plant stalks, themethod comprising: cutting plants growing in a field by a headerapparatus and placing the plants as crop materials on a path through aforage harvester; using the forage harvester to chop the crop materialsin a manner to produce stalk pieces having lengths of approximately 1inch to approximately 2.5 inches long; and processing the crop materialsusing rolls to rip a plurality of the stalk pieces in a lengthwisedirection of the stalk piece so as to produce feed for animals, whereinthe rolls are positioned with a gap in between of approximately 0.01inches to approximately 0.24 inches, the rolls are controlled to rotateat a speed differential of at least ten percent, the first roll includesa plurality of alternating longitudinal ridges and grooves and at leastone circumferential groove having a depth of less than 0.5 inches thatcrosses the longitudinal ridges and grooves to form a plurality of gapsalong the longitudinal ridges to form tooth segments between the ends ofthe first roll, the tooth segments substantially extend in alongitudinal direction of the roll, and the tooth segments havelongitudinal lengths of less than 1 inch and have smaller outer edgesforming sharp cutting teeth far easier penetration and effective tearingof plant stalk while the rolls of the processor are spaced apart.
 9. Themethod of claim 8, further comprising: fracturing of kernels obtainedwith the crop materials.
 10. The method of claim 8, wherein the stalkpieces are processed by a processor apparatus and travel through theprocessor apparatus with their longest axis oriented substantiallyparallel to the direction of movement through the processor apparatus.11. The method of claim 8, wherein the rolls are comprised of two rollseach having alternating ridges and grooves.
 12. The method of claim 8,wherein processing further comprises providing the rolls with diametersgreater than approximately 10 inches.
 13. The method of claim 8, whereinprocessing further comprises providing the rolls with at least oneV-shaped circumferential groove.
 14. The method of claim 8 additionallycomprising: feeding the processed pieces of plants to a ruminant animal.15. The method of claim 8, wherein the at least one circumferentialgroove is a spiral groove.